CN105706153A - Virtual reality and real welding training system and method - Google Patents

Abstract

The invention relates to virtual reality and real welding training system and method. A virtual welding station (100) includes a virtual sequencer (186) for simulating different welding techniques and non-welding operations. The virtual welding station can be used to train an operator on the production of complete assemblies.

Description

Virtual reality and reality weld training system and method

The present invention relates to virtual welding system according to claim 1。The application faces patent application submission as non-, it is desirable to the priority/rights and interests of the U.S. Provisional Patent Application number 61/900,136 submitted on November 5th, 2013 under 35U.S.C. § 119 (e), its whole disclosure contents are incorporated herein by reference。

Invention field

The present invention relates to welding station simulation field, and relate more specifically to the virtual sequencer of the semi-automatic welding of Simulation of Complex assembly。

Technical background

How study performs Overall Steps required in welding station, including the step except welding, to expend the time of a lot of guidance, training and exercise traditionally。

There is a lot of different types of operation to learn, operate including various welding and non-solder。Generally, the step of welding station is by student operator in reality welding station study, and reality metalwork is subjected to by student operator。The training of this real world is likely to take rare welding resource and exhaust limited welding material。Because operator learns assembly manipulation, reality manufactured parts is trained possible relatively costly while welding。Training time on reality manufactured parts typically requires two operators (cost is high) and likely produces particle, does over again or low quality assembly。

But recently, use the idea that welding analog is trained to become increasingly prevalent。Some welding analogs are realized by personal computer, are realized by the Internet online or even realize as virtual welder。But, conventional welding analog tendency is limited to single pad on their training emphasis and generally once relates to a kind of solder technology。Conventional virtual reality training generally only relates to independent pad and does not prepare or train how welding person produces complete assembly, and described complete assemblies relates to multiple welding and/or installation step。It practice, be different from these simulators, much different solder technology and non-solder operation, these technology and operation is needed to need to produce weld assembly overall, complete at welding station。Accordingly, there exist the unsatisfied demand of a kind of butt welding grafting simulation system and method, these system and methods can simulate the production of complete assemblies effectively。

Explanation

In order to effectively simulate the production of complete assemblies, disclose virtual welding system according to claim 1。Further embodiment of the present invention is the theme of dependent claims。General inventive concept comprises virtual welding system (and correlation technique), including disclosed herein and suggestion demonstrative system and method。

In one exemplary embodiment, a kind of virtual welding system includes: the subsystem of a logic-based processor, described subsystem can be used to the coded command performed for producing interactive welding surroundings, the welding activity on virtual plumb joint that described interactive welding surroundings simulation at least one in welding piece and exemplar limits；One virtual sequential controller, described virtual sequential controller is operatively connectable to the subsystem of described logic-based processor for realizing virtual sequential；Display device, described display device is operatively connectable to the subsystem of described logic-based processor visually to describe to include the described interactive welding surroundings of described virtual plumb joint；One input equipment, described input equipment for carrying out virtual welding activity in real time on described virtual plumb joint；And a spatial pursuit device, described spatial pursuit device includes one or more sensor, and the one or more sensor is adapted for the movement of input equipment described in real-time tracing the data relevant with the movement of described input equipment to be transferred to the subsystem of described logic-based processor。

In one exemplary embodiment, described virtual welding system farther includes a user interface, provides input for a user to described virtual welding system。

In one exemplary embodiment, the subsystem encapsulation of described logic-based processor is in a simulation welding control station, and size and the shape of described simulation welding control station are confirmed as an approximate source of welding current。

In one exemplary embodiment, the subsystem that described logic-based processes realizes described virtual sequential controller。

In one exemplary embodiment, described virtual sequential controller includes a microprocessor, a sequence control program and a memorizer。Described memorizer stores one or more state table files。

In one exemplary embodiment, described virtual welding system farther includes a virtual sequential configuration tool。Described virtual sequential configuration tool allows user to revise one of existing state table file。Described virtual sequential configuration tool allows to create new user state table file, in order to store in memory。

In one exemplary embodiment, described virtual sequential is to be defined by least one in described state table file。

In one exemplary embodiment, user is based on there being one of state table file described in pending task choosing。In one exemplary embodiment, described task is to produce complete virtual component。

In one exemplary embodiment, described virtual sequential includes the multi-mode operation needing to be performed in order, and each operation aims at a particular state。

In one exemplary embodiment, at least one in described operation is that described user has pending manual operation。In one exemplary embodiment, described manual operation is to provide user information, retrieval part, provides parts information, placement part, retaining element and provide the one in module information。

In one exemplary embodiment, described virtual welding system farther includes virtual sequential display device。Described virtual sequential display device shows the information relevant with described manual operation。

In one exemplary embodiment, at least one in described operation is that described virtual welding system has pending automatic operation。In one exemplary embodiment, described automatic operation is appointment welding procedure, designated gas type, designated gas flow velocity, appointment welding rod type, appointment flux-cored wire type, appointment wire feed rate, specified voltage level, appointment amperage, appointment polarity and is the one in described interactive mode welding surroundings specific context environment。

In one exemplary embodiment, at least one in described operation is that described user has pending manual operation；And at least one in described operation is that described virtual welding system has pending automatic operation。

In one exemplary embodiment, each state is associated with a condition。In one exemplary embodiment, if condition described in not met, described sequence controller performs an action。In one exemplary embodiment, described action is to wait for predetermined duration。In one exemplary embodiment, described action is the operation being recycled and reused for described state。In one exemplary embodiment, described action is to restart described virtual sequential。

In one exemplary embodiment, described virtual sequential includes from the group being made up of the following selection analog functuion: quality examination (QualityCheck) function, repetitions (Repeat) function, notify welder (NotifyWelder) function, input operation (EnterJob) function, workpaper (JobReport) function, systems inspection (SystemCheck) function, execution welding operation (PerformWeldingOperation) function and their combination。

In one exemplary embodiment, described display device includes lcd screen。

In one exemplary embodiment, described display device is to wear in the display of face。In one exemplary embodiment, wear the display in face described in be incorporated in welder's helmet。In one exemplary embodiment, described welder's helmet includes at least one speaker。

In one exemplary embodiment, described display device includes the first display and second display。Described first display is to wear in the display of face, and described second display is not wear in the display of face。

In one exemplary embodiment, described first display and described second display can be used to (simultaneously) and present the different views of interactive welding surroundings。

In one exemplary embodiment, described display device can be used to and communicates on network。In one exemplary embodiment, described network is wireless network。

In one exemplary embodiment, described input equipment is simulation soldering appliance。

In one exemplary embodiment, described input equipment can be used to and communicates on network。In one exemplary embodiment, described network is wireless network。

In one exemplary embodiment, described spatial pursuit device produces magnetic field。Described magnetic field can be used to determines the position of one or more sensors in described magnetic field。

In one exemplary embodiment, described virtual welding system farther includes supporting construction。

In one exemplary embodiment, described supporting construction is frame。In one exemplary embodiment, described frame includes a base, a column, an adjustable bed and an adjustable arm。In one exemplary embodiment, described welding piece can be used to and is attached to described frame。In one exemplary embodiment, at least one clamp is for being attached to described frame by described welding piece。

In one exemplary embodiment, described supporting construction is assembling jig。In one exemplary embodiment, described assembling jig holds described exemplar。

In one exemplary embodiment, described virtual welding system farther includes to collect from described virtual sequential controller and store welding and the device of operation data。

In one exemplary embodiment, described virtual welding system farther includes the device for distributing quality score to described virtual welding activity。

Brief Description Of Drawings

Accompanying drawing combines in the description and constitutes one part, in the accompanying drawings, illustrates the different exemplary embodiments of the present invention, and accompanying drawing is used for illustration embodiments of the invention together with summary description given above and detailed description given below。

The block diagram of Fig. 1, illustrates the system according to exemplary embodiment, and described system provides the arc welding training in real-time virtual actual environment；

Fig. 2 is block diagram, illustrates simulation welding control station and observer's display device (ODD) of the system of the Fig. 1 according to exemplary embodiment；

Fig. 3 is sketch, illustrates simulation welding control station and sequencer display/user interface (SDUI) of the system of the Fig. 1 according to exemplary embodiment；

Fig. 4 is sketch, illustrates the workbench/frame (T/S) of the system of the Fig. 1 according to exemplary embodiment；

Fig. 5 be draw, illustrate the Fig. 1 according to exemplary embodiment system assembling jig in exemplar (weldment)；

Fig. 6 draws, and illustrates the different elements of the spatial pursuit device (ST) of the system of the Fig. 1 according to exemplary embodiment；

Fig. 7 is block diagram, further illustrates the system of the Fig. 1 according to exemplary embodiment；

Fig. 8 is flow chart, illustrates the sequencer logic according to exemplary embodiment；

Fig. 9 is system schematic, illustrates the virtual system of the virtual sequencer controller with repeatable programming according to exemplary embodiment；

Figure 10 is schematic diagram, further illustrates the virtual sequencer controller of exemplary repeatable programming of Fig. 9；

Figure 11 is flow chart, illustrates the condition inspection in the example virtual sequencer controller of Fig. 9 and Figure 10；

Figure 12 is flow chart, illustrates the operation of sequence control program in the example virtual sequencer controller of Fig. 9 and Figure 10；

Figure 13 is flow chart, illustrates the exemplary operation included at virtual sequential according to exemplary embodiment, and described virtual sequential adopts semi-automatic welding work unit；

Figure 14 is flow chart, illustrates the training routine according to exemplary embodiment；

Figure 15 is flow chart, illustrates the training routine using virtual score according to exemplary embodiment；

Figure 16 is flow chart, illustrates the recruitment that the use virtual performance according to exemplary embodiment is measured；

Figure 17 is flow chart, illustrates the optimization routine using virtual welding station according to exemplary embodiment；

Figure 18 is flow chart, illustrates the training routine using virtual score and real world mark according to exemplary embodiment；

Figure 19 is flow chart, illustrates the training routine using virtual score and real world mark according to exemplary embodiment；And

Figure 20 is flow chart, illustrates use virtual score and real world mark according to exemplary embodiment and determines how phantom station predicts the routine of real world representation well。

Describe in detail

In the exemplary embodiment, virtual (simulation) welding station includes virtual welding job sequencer。Virtual welding job sequencer is in virtual environment or uses one or more virtual component (such as virtual welding machine) simulating reality world welding job sequencer (such as, the welding sequencer (WeldSequencer) of The Lincoln Electric Company of the U.S. (LincolnElectric))。Real world welding job sequencer can control the operation of semi-automatic work cell, including instructing operator what next makes and automatically changes some parameter of welding unit, including such as welding parameter。Real world welding job sequencer can provide series of orders and instruction for operator, and these orders are relevant with instruction and the welding of operation and the non-solder aspect being associated with welding station。

Virtual welding station including virtual sequencer can include LincolnElectric company(virtual reality arc welding training airplane) and be incorporated into virtual welding station to create the welding sequencer technology of unique training/test environment。In virtual welding station, VRTEX system can use welding sequence to be used for virtual reality training to produce the assembly given。These needs carry out a series of virtual welding in virtual component, and these are welded on the welding process required for production reality components, operation and program (independent welding adds complete job guide) aspect training operator。Once complete virtual training, operator creates the real world welding process required for reality components and event sequence by preparing。After using the training of virtual sequencer, present operator uses welding sequencer to produce reality components, and repeats identical welding sequence。Reality welding operation, by welding sequencer control and monitoring, uses welding mark (WeldScore) to monitor welding process simultaneously。Welding mark monitor includes but not limited to the embodiment disclosed in the United States serial 12/775,729 (being U.S. Patent number 8,569,646 now) submitted on May 7th, 2010, and it is incorporated herein by reference in full。

In the exemplary embodiment, all of training data (from VRTEX and welding sequencer) is collected in production monitoring system。Use this technology to provide comprehensive course project (having virtual component to create and reality components creation)。This includes the common welding sequence being used in virtual (VRTEX) environment and reality welding sequencer controller (the part workbox together with being used for the real welding portion trained)。The end result of independent course is the complete report of the real part in all training welding/operation, time assembly period and workbox。

Operation order (is used in virtual and real world environments) can comprise the validity check to parameter, as placing part, gait of march (welding duration), average amperage and other welding variablees。The use of these common requirement enhance first virtual welding station learning and hereafter on reality components repeat actual requirement (simultaneously virtual sequencer and welding sequencer in the same manner operation instructed respectively and monitor)。

Being successfully completed of virtual training can include the gross score of number of times and other welding variablees starting/stopping for all welding operations, total gate, total electric arc time limit, electric arc。Once reach minimum requirements (such as, once performance mark reaches predetermined threshold value), approval operator carries out including the next training step of reality welding。

In reality welding process, welding sequencer is by same weld order identical with the virtual sequencer being successfully completed reality components for instructions for use。

Welding and the operation data of coming self-virtualizing sequencer and welding sequencer operations can be collected in common production monitoring system (such as, inspection post (CheckPoint))。Data can by operator, welding operation (virtual and real), the quantity of assembly produced, mass fraction, cycle time tolerance etc. collect。

In the exemplary embodiment, as real world sequencer, virtual sequencer can automatically select and realize the function of virtual welding job unit。Such as, function can include the concrete virtual welding plan that will be used in virtual work unit。In other words, the virtual welding that virtual sequencer can be concrete selects there is virtual welding plan to be used, and automatically revises the setting (namely, it is not necessary to the specific intervention of operator) of virtual work unit for operator according to selected virtual welding plan。

It addition, in the exemplary embodiment, virtual sequencer can automatically indicate that operation order, step or different pads that operator should defer to are to produce final virtual component。Automatically selecting of combined with virtual welding plan, the order of this instruction allows operator to defer to described order to produce final virtual component, expects in the welding station of real world just as desired operation person doing。

Accordingly, because virtual sequencer is set up virtual welding equipment and organized workflow, just as real world sequencer, therefore begin at operator before real world welding unit or welding station operate, virtual sequencer can be used to train them。In this way, greatly reduce the chance of mistake in real world welding station and improve productivity ratio and quality。

In illustrative examples, virtual reality welding station (VRWS) includes the subsystem based on programmable processor, is operatively connectable to the spatial pursuit device of the subsystem based on programmable processor, can be simulated soldering appliance by spatial pursuit device at least one of spatial pursuit and be operatively connectable at least one display device of the subsystem based on programmable processor。VRWS can simulate the operation being associated with real world welding station in virtual reality space。These operations can include various types of welding and non-solder operation。For welding operation, VRWS can the welding pool of display simulation in real time on the display device。As used herein, term " in real time " mean by with user real world weld under sight will perception and experience identical in the way of, perception and experience in time under the environment of simulation。Non-solder is operated, for instance identifying input/scanning, Parts Recognition input/scanning, part clamping, fixture manipulation/control, inspection etc. as operator, system can repeat and/or simulated operation person completes the step required for welding operation at concrete welding station。Generally, VRWS can include any one in the feature that discloses in following patent application and ability or all, the full text of each application of these patent applications is incorporated herein by reference。The United States serial 11/227,349 of JIUYUE in 2005 submission on the 15th, is U.S. Patent number 8,692,157 now；The United States serial 11/613,652 of December in 2006 submission on the 20th；The United States serial 12/501,257 that on July 10th, 2009 submits to, is U.S. Patent number 8,747,116 now；The United States serial 12/501,263 that on July 10th, 2009 submits to；The United States serial 12/504,870 that on July 17th, 2009 submits to；The United States serial 12/719,053 that on March 8th, 2010 submits to, is U.S. Patent number 8,274,013 now；The United States serial 13/081,725 that on April 7th, 2011 submits to, is U.S. Patent number 8,657,605 now；The United States serial 13/364,489 that on February 2nd, 2012 submits to；The United States serial 13/720,300 of December in 2012 submission on the 19th, is U.S. Patent number 8,787,051 now；The United States serial 13/792,288 that on March 11st, 2013 submits to, is U.S. Patent number 8,834,168 now；The United States serial 13/792,309 that on March 11st, 2013 submits to；The United States serial 13/792,294 that on March 11st, 2013 submits to, is U.S. Patent number 8,851,896 now；The United States serial 13/792,280 that on March 11st, 2013 submits to；And the United States serial 13/545,058 that on July 10th, 2012 submits to。

With reference now to accompanying drawing, what provide accompanying drawing is intended that different exemplary embodiments that are bright disclosed herein or that otherwise advise rather than in order to limit them, Fig. 1 illustrates the exemplary embodiment of the system block diagram of system 100, and described system is for providing the welding station in real-time virtual actual environment to train。System 100 includes the subsystem (PPS) 110 based on programmable processor。System 100 farther includes to be operatively connectable to the spatial pursuit device (ST) 120 of PPS110。System 100 also includes the physical weld user interface (WUI) 130 being operatively connectable to PPS110 and what be operatively connectable to PPS110 and ST120 wears in the display device (FMDD) 140 of face。System 100 can also include the observer's display device (ODD) 150 being operatively connectable to PPS110。System 100 can also include at least one simulation soldering appliance (MWT) 160 being operatively connectable to ST120 and PPS100。System 100 can include workbench/frame (T/S) 170。System 100 can also include at least one welding piece (WC) 180 that can be attached to T/S170。System 100 can include assembling jig (AF) 182。System 100 can also include at least one exemplar (SP) 184。System 100 also includes virtual sequencer (VS) 186 and sequencer display/user interface (SDUI) 188。In other exemplary embodiments, VS186 can combine with PPS110 and/or SDUI188 can combine with WUI130 and/or other interface, display etc., in order to simulates quantity and the type of interface and/or the display needing site operator mutual in real world welding station。

System 100 can also include other equipment various, for instance as operation equipment 190, the real world welding station equipment that some operation of described operation equipment simulating is required。As it is shown in figure 1, operation equipment 190 can be associated with AF182 so that the position putting, manipulating AF182 of the SP184 in such as checking AF182, to make one or more clip that SP184 is retained on AF182 medium。Other equipment (not shown) can include such as scanner, reader, user interface, display (includes such as configurable vision to help), vision/sound indicator is (such as, for sequence error, weld out-of-limit, welding mark defects detection), PLC interface, linkage is (such as, preheating and/or interpass temperature, the position of autonavigator, piece test/part loads, clip closed/open), control panel, assembly tool, checking tool, operator's position sensor is (such as, body weight sensor pad), part position/proximity sensor, safety/interlock, Lighting control, raw material haulage equipment, part and/or assembly instrument are (such as, for quality control) etc.。According to other exemplary enforcement, it is provided that simulation gas cylinder (not shown) is simulated protection source of the gas and has adjustable flow actuator。Some elements in the above element of system 100 can be used in the real world parts in virtual welding station。Such as, real world assembling jig 182 can be used for holding exemplar 184。Virtual and real world parts combination in any can include virtual welding station。

Fig. 2 illustrates the exemplary embodiment of the simulation welding control station 135 with observer's display device (ODD) 150 of the system 100 of Fig. 1。Physics WUI130 resides in the front portion of control station 135 and provides knob, button and stick, selects various patterns and function for user。Optional ODD150 is attached to the top of control station 135。MWT160 resides in the holder of the sidepiece being attached to control station 135。In inside, control station 135 can hold or the various parts of otherwise package system 100, for instance, a part of PPS110, VS186 and/or ST120。

Fig. 3 illustrates the welding control station 135 (simulation source of welding current user interface) of the system 100 of Fig. 1 and the exemplary embodiment of SDUI188。Also show the zoomed-in view of the exemplary screen shot 189 of SDUI188。Physics SDUI188 can provide display screen, knob, button and/or stick, selects various patterns and function for user。VS186 can be integrally forming with SDUI188 and maybe can include in PPS110, and PPS can include in control station 135。

Fig. 4 illustrates the exemplary embodiment of the workbench/frame (T/S) 170 of the system 100 of Fig. 1。T/S170 includes adjustable bed 171, frame or base 172, adjustable arm 173 and column 174。Workbench 171, base 172 and arm 173 are attached to column 174。Workbench 171 and arm 173 each manually can regulate relative to column 174 upwards, downwards and rotatably。Arm 173 is used for holding various welding piece (such as, welding piece 175) and/or exemplar 184, and his/her arm can be placed on workbench 171 by user when training。Column 174 is labeled with positional information so that user can know arm 173 definitely and workbench 171 is vertically located in where go post 174。User can use WUI130, ODD150 and/or SDUI188 this vertical position information to be input in system。

Fig. 5 illustrates example assembled fixture (AF) 182, and described assembling jig is shown as single adjustable supports structure。Described supporting construction is depicted as fixing (that is, supporting) exemplar (SP) 184, i.e. have the weldment of spaced apart track 514,516。Supporting construction 182 includes top moveable platform 518, holds the upper surface 520 of weldment 184 on the platform。For being used for simulating the concrete region of weldment 184 of welding, can move platform 518 regulate to desired position and towards。Weldment 184 is being enclosed by elongated with 524 (illustrate only short section of elongated band in Fig. 5) frame around framework 522。When being merged in rail system, the upper surface 520 of weldment 184 is the upside of rail section。Support that structure 526 is positioned on spaced apart position along the length of weldment 184。As shown in this drawing, support structure 526 being positioned to have track 514,516, these tracks are between the outside of the framework 522 of support 526 and weldment 184。Paying close attention to further supporting construction 182, bottom is fixed support base 528 and is operably connected top moveable platform 518 by spaced multiposition hinge 530,532。In one embodiment, multiposition hinge can be 2 linkages, and parts or element 530,532 are mainly called 2 linkages by following discussion。It should be appreciated, however, that under the scope not necessarily departing from general inventive concept and intention situation, it is possible to use permit other hinges or other suitable structures that moveable platform 518 suitably moves。Moveable platform 518 can be controlled by the operation equipment 190 of the system 100 of Fig. 1。It addition, the supporting construction 182 (such as AF) described in Fig. 5 and weldment 184 (such as SP) are merely exemplary。AF182 and SP184 can include the arbitrary shape needed for any welding operation, structure, number of parts, part type and part dimension。

As mentioned, it is possible to regulate supporting construction 182 weldment 184 is navigated to be suitable for required simulation welding operation towards and position。In order to regulate the top moveable platform 518 position relative to fixing support base 528, actuator (such as length adjustment component 550,552) is connected between pivot or pivoting member 540,542 and pivot or pivoting member 554 and 556, and latter of which is usually located at the immediate vicinity of firm banking 528。It addition, actuator (such as length adjustment component 560) is connected to fixing support between base 528 and moveable platform 518 via pivot or pivoting member 556 and pivot or pivoting member 562。The location of length adjustment component 550,552 and 560 determines the position of moveable platform 518 and therefore determines the position of the weldment 184 of carrying on it。Pivoting member 530c, 532c, 530d, 532d, 540,542,554,556 and 562 provide the supporting construction 182 with 3 degree of freedom, i.e. can move up in x and z side, also be able in x-z-plane to tilt。The physics size of independent length adjustment component 550,552,560 and operating feature are for determining the sports envelope of supporting mechanism 182。Although in one exemplary embodiment, length adjustment component is hydraulic actuator, but they also may indicate that other actuators, such as pneumatic actuator, ball-screw actuator and/or any type of automatically controlled actuator。Any or whole parts of these movable parts can be controlled by one or more operation equipment 190 of the system 100 of Fig. 1。

Other exemplary embodiments can include one or more the combination in any in workbench 171, arm 173, assembling jig 182, test specimen 180 and/or exemplar 184, in order to simulates the real world welding station operation being modeled best。

According to other exemplary embodiments, the position of workbench 171, arm 173 and/or AF182 can be automatically set by PSS110 and/or VS186 by WUI130, ODD150 and/or SDUI188 of arranging or being required by user of pre-programmed。In such an embodiment, T/S170 and/or AF182 generally includes such as motor and/or servo control mechanism, and activates motor and/or servo control mechanism from the signal command of the said equipment。

According to further exemplary embodiment, workbench 171, arm 173, AF182, WC180 and/or SP184 position can be detected by system 100。So, user manually inputs positional information without going through user interface。In such an embodiment, T/S170 and/or AF182 includes position and towards detector and send the signal instruction providing position and orientation information to PPS110 and/or VS186。WC175 and/or SP184 can include position-detection sensor (such as, for detecting the coiling sensor in magnetic field)。According to exemplary embodiment, when regulating parameter change, user is it can be seen that T/S170's and/or AF182 on ODD150, FMDD140 and/or SDUI188 presents。

According to further exemplary embodiment, workbench 171, arm 173, AF182, WC180 and/or SP184 position can be specified by system 100 and be monitored。In different exemplary embodiments, workbench 171, arm 173, AF182, WC180 and/or SP184 position can be controlled based on the order of PPS110 and/or VS186 by operation equipment 190。In other exemplary enforcements, user can pass through user interface provide positional information and manually positioning table 171, arm 173, AF182, WC180 and/or SP184。Determine based on the real world welding station operation simulated and automatically and manually position。

Other operation equipment 190 various can include in VRWS, in order to simulating reality world welding station。Control with these equipment and communication is designed to be used in virtual and/or real world equipment and parts (being similar to exemplary AF182 described herein) carry out simulating reality world welding surroundings。

Fig. 6 illustrates the different elements in the exemplary embodiment of the spatial pursuit device (ST) 120 of Fig. 1。ST120 is able to the magnetic tracker that the PPS110 operatively interface with system 100 is connected。ST120 includes the host software on magnetic source 121 and source cable, at least one sensor 122 and associated cables, disk 123, power supply 124 and associated cables, USB and RS-232 cable 125 and processor tracing unit 126。Being operable to property of magnetic source 121 it is connected to processor tracing unit 126 or otherwise interfaces connection (such as, passing through cable)。Being operable to property of sensor 122 it is connected to processor tracing unit 126 or otherwise interfaces connection (such as, passing through cable)。Being operable to property of power supply 124 it is connected to processor tracing unit 126 or otherwise interfaces connection (such as, passing through cable)。Processor tracing unit 126 can pass through USB or RS-232 cable 125 and is operatively connectable to PPS110 or otherwise interfaces connection。Host software on disk 123 can be loaded on PPS110 and allow the function communication between ST120 and PPS110。

As shown in Figure 4, the magnetic source 121 of ST120 is arranged on the Part I of arm 173 or otherwise interfaces connection。Magnetic source 121 with reference to Fig. 5, ST120 is arranged on the rear portion of upper brace 18 or otherwise interfaces connection。In other exemplary embodiments, multiple magnetic sources 121 are arranged on diverse location and can be used for providing suitable tracking。Magnetic source 121 produces magnetic field around magnetic source 121, and including the space surrounding WC175 and SP184, described space establishes 3d space reference frame。T/S170 and/or assembling jig 182 can major part be nonmetallic (non-ferric and non-conductive), from the distortion of field without making magnetic source 121 produce。Sensor 122 can include three induction coils along three direction in space orthogonal arrangement。The induction coil of sensor 122 each can be measured the magnetic field intensity in each in three directions and that information is supplied to processor tracing unit 126。Therefore, system 100 is able to know that where the 3d space reference frame that the arbitrary portion of WC175 and/or SP184 is set up relative to magnetic field is positioned at。Sensor 122 can be attached to MWT160 or FMDD140, thus allow MWT160 or FMDD140 space and towards on be tracked relative to 3d space reference frame by ST120。When two sensors 122 are provided and are operatively coupled to processor tracing unit 126, both MWT160 and FMDD140 can be tracked。In this way, system 100 can produce virtual WC, virtual SP, virtual MWT, virtual T/S and/or virtual AF in virtual reality space, and shows virtual WC, virtual SP, virtual MWT, virtual T/S and/or virtual AF on FMDD140, ODD150 and/or SDUI188 when following the trail of MWT160 and FMDD140 relative to 3d space reference frame。

According to another exemplary embodiment, sensor 122 wirelessly can be connected to processor tracing unit 126 by interface, and processor tracing unit 126 wirelessly can be connected to PPS110 by interface。According to other exemplary embodiments, other kinds of spatial pursuit device 120 can be used within system 100, including such as based on the tracker of accelerometer/gyroscope, optical tracker (active or passive type), infrared tracker, sound tracing device, laser traces device, radio-frequency tracking device, inertia tracker and the tracing system based on augmented reality。Other kinds of tracker is also possible。In some exemplary embodiments, it is possible to use the combination of two or more different tracer techniques。

Fig. 7 illustrates the exemplary embodiment of Fig. 1 system 100。The various functional modules of the system 100 shown in Fig. 7 realize mainly through software instruction and the module run on PPS110 and/or VS186。The various functional modules of system 100 include physical interface 701 soon, blowtorch and fixture model 702, environmental model 703, sound-content function 704, welding sound 705, assembling jig/frame/working model 706, inside structure function 707, calibration function 708, operation mounted cast 709, exemplar/test specimen model 710, weld physics part 711, internal physical part regulates instrument (adjusting apparatus (tweaker)) 712, graphical user interface function 713, drawing function 714, student's reporting functions 715, present device 716, bead presents 717, 3D texture 718, visual cues function 719, scoring and tolerance function 720, tolerance editing machine 721, specially good effect 722, and order model 723。

The functionally similar mode that the function of each frame shown in Fig. 7 discloses with United States serial 12/501,257 mentioned above operates, and it is incorporated herein by reference in full。The modeling of AF182 can be similar to the T/S170 in frame 706。The modeling of SP184 can be similar to the WC180 in frame 710。Graphical user interface function 713 can also include SDUI188 setting up/operation of the welding station scene of display simulation and step。According to exemplary embodiment, setting up of welding scene includes selecting language, input user name and selecting the welding station of simulation。According to selected welding station, VS186 can select suitable order model from frame 723。Order model 723 will include the various aspects being associated with the operation of selected welding station, thus specifying procedure of processing, including such as specifying WC180 and/or SP184；Specify T/S170 configuration and/or AF182；Specify one or more welding procedure (such as, FCAW, GMAW, SMAW) and axially spraying, pulse or the short arc method that are associated；Designated gas type and flow velocity；Specify the type of welding rod；Specify the type of flux-cored wire (such as, self-shield, gas shield)；Designated environment (such as, the background environment in virtual reality space)；Specify wire feed rate；Specified voltage level；Specify amperage；Specify polarity；And open or close concrete visual cues。In other exemplary embodiments, according to the decision-making that operator in the real world welding station process of simulation must specify, it is possible to prompting user specifies some option and/or parameter。

System 100 can analyze and show the result that virtual welding station is movable。By analyzing described result, it is meant that system 100 can determine when user deviate from the acceptable boundary of the process specified in the procedure of processing (including welding and non-solder operation) specified。Can mark according to the performance of user。In one exemplary embodiment, mark can be the function of herein below: the operation of omission；Incorrect fixing part；And the position of simulation soldering appliance 160, towards with speed deviation (tolerance is likely to extend to critical or unacceptable welding activity from desirable welding bead) in the whole margin of tolerance, the quality examination omitted or any other operation of being associated with selected welding station。

Visual cues function 719 can be covered by display on FMDD140, ODD150 and/or SDUI188 and add color and indicator and to provide immediate feedback to user。Visual cues can be provided for multiple parts of each operation in the operation being associated with selected welding station or each operation。

Fig. 8 is the flow chart of the sequencer logic according to exemplary embodiment。In the exemplified embodiment, virtual sequencer command operating person can perform any number of operation with simulating reality world welding station。Such as, virtual sequencer command operating person can perform operation 1 to reach particular state。Operation 1 complete can also be associated with condition inspection。If condition unmet (such as, do not input dash number, part be not placed in fixture, welding duration fall short of), order can take action, for instance, as wait, reissue commands, stopping or any other action。These actions can be designed to action required in simulating reality world welding station maybe can deviate real world welding station, in order to provides for operator and better trains experience (such as, reissue commands)。When completing all operations (and meeting the condition being associated) for virtual welding station, order just completes。

Fig. 9 to Figure 12 describes the control system according to exemplary embodiment。With reference now to Fig. 9 to Figure 11, it is shown that the Exemplary control system 902 of the system 100 of Fig. 1。In different embodiments, control system 902 can be embedded in PPS110, VS186, simulation welding control station 135 and/or other group portions。System 902 includes multiple welding system parts 950, generally these parts are virtual components, including power supply 951, wire feeder 952, moving carriage 953, gas solenoid 954, coolant solenoid 955, smog extraction system 956 and robot or programmable logic controller (PLC) (PLC) 957, system unit 950 shown in it is only example, and according to general inventive concept, it is possible to provide more or less of parts for system。Virtual welding assembly may be embodied in the welding control station 135 of simulation, such as 2。If some parts can not be simulated fully, real world welding or non-solder parts are usable in virtual welding station。

As shown in Figure 10, system 902 farther includes the virtual sequencer controller 910 with microprocessor 912, sequence control program 922, and one or more state table file 924, 926, 928, wherein virtual sequencer controller 910 also provides for various interface, these interfaces include the network interface 914 for sequencer 910 and network 930 being operatively connected, one or more private communication interfaces 916 by cable 940 offer with the direct communication connectivity of the one or more system units in system unit 950, and user interface 918 is (such as, SDUI188 as Fig. 1), described user interface provides operator or user to the access of sequencer 910 for arranging parameter, value etc., and/or for presenting operation information to user。

As shown in Figure 8, network 930 can by the one or more system units in system unit 950 and controller 910 and be coupled to each other and also provide data sharing and the exchange of other information between any one and external device (ED) or other network (not shown) in parts 910,950。This includes being connected to consolidated network as real world welding station。

And, alternatively or in combination, specific cables 940 can be used for interconnecting sequencer 910 with some or all parts in welding system parts 950, as power supply controls cable 941, wire feeder cable 942, moving carriage cable 943, gas controls cable 944, coolant solenoid controls cable 945, smog extracts and controls cable 946, and/or robot or PLC cable 947, wherein connected by the interface of network 930 (and network interface 914) and/or cable 940 (and interface 916) and provide data or other information, signaling, the exchange of message etc., by this exchange, sequential control input 921 can be obtained from one or more system units 950 and sequential control exports the 923 one or more parts that can be supplied to parts 950。

In one exemplary embodiment, processor 912 is microprocessor, microcontroller, DSP, programmable logic device etc., although any form of computing parts can be used in the scope of general inventive concept, no matter it is hardware, software, firmware or their combination, and they can be single assemblies or can realize in multiple parts。Further note that, controller 910 can be incorporated into one of system unit 950 (such as power supply 951, wire feeder 952 etc.), wherein user interface 918 can include one or more display device, user control handle, switch, keypad etc., and can be connected by those aspect interfaces of user some aspects with system unit 950 and sequencer controller 910。And, controller 910 includes memorizer 920, it described memorizer can be the data storage (integrated form or distributed) being arbitrarily suitable for, couple with processor 912 to storage operation, with the file allowing processor 912 to be stored in processor 920, program, instruction, routine, data etc.。Although it should be noted that processing component 912 and memorizer 920 may be integrally incorporated in parts, such as single circuit board, but these elements can individually provide or be distributed in multiple system unit to provide controller 910 within the scope of general inventive concept。Memorizer 920 storage order controls program 922 and state table file 924,926,928, it is provided that it is accessed by processor 912。Memorizer 920 can also include the instrument of being arranged in order 929, such as the software program that can also be performed by processor 912。State can be used for defining the different phase of assembling process, including individually operated (such as, part in fixture, weld interval etc.) intended semi-automatic or manual mode and/or the auto state (change of the welding parameter such as, occurred in single welding process) being automatically controlled that occurs in operation when terminating。

In the exemplary embodiment, exemplary power 951 and miscellaneous part are based on state table, and some output in its middle controller output 923 is supplied to parts as input 996。In operation, required output stage or multiple output stage are exported 923 as one or more controllers and provide and be supplied to various virtual component by controller 910, and these parts adopt these output stages to define and regulate the required state of parts。Such as, controller 910 can regulate concrete welded condition, concrete holder status etc.。Microprocessor 912 performs standard routines according to sequence control program, and described standard routines simulates all operations (and associated parameter) being associated with the welding station specified。Controller can read each state, regulate the instruction being associated with current state and determine that a series of condition checks whether is true, and if it is, transfers to next state (or operation)。

In some exemplary embodiments, it is possible to carry out some and check to ensure that order prepares to proceed to the next item down operation。Figure 11 illustrates the operation of exemplary control process 962, and including condition inspection, wherein the first state table and tables of data obtain 1152 in 1150 loadings and input value。Calculate parameter 1154 and perform status command, be hereafter loaded into first condition inspection 1156 and carry out testing (such as, true or false) 1158。If first condition is genuine (1158 for being (YES)), then perform the instruction being associated in 1160 programs 962, update intervalometer 1162, and jump to corresponding NextState 1164, hereafter it is updated 1166 pairs of outputs, and program 962 returns to 1152。If the first test condition is not true (being no (NO) 1158), then determine whether to specify more inspection for current state 1170, and if (being yes 1170), it is loaded into next condition inspection 1172, and as it has been described above, program tests new condition 1158。Once find that current state is not genuine (being no 1170) by all conditions inspection, 1174, program 962 updates intervalometer, updates output 1166, then returns to 1152 again as described above。

With reference to Figure 12, processor 912 inputs 921 according to sequence controller and controls program 922 in proper order according to sequential control state table file 924,926, the 928 execution example virtual selected, to provide sequence controller output 923, thereby through the function to realize specifying by state (or progressively) mode to perform pseudo operation, its conditional inspection provides and transfers to suitable NextState based on input, intervalometer etc.。In operation, using the selection feature on sequencer user interface 918, user carries out selecting (such as, virtual welding station order) from available state table file 924,926,928。The execution controlling program 922 in fig. 12 in proper order starts from 1202, wherein 1204, processing component 912 obtains current sequential control state table file item from sequential control state table file 924, and obtains the current input of controller in proper order 921 at 1206 at least one parts from virtual system parts。1208, processor 912 performs one or more executable instructions or the routine (using one or more order parameter) of the control program 922 that the instruction identifier of currentitem identifies, and provides sequence controllers output 923 1210。The virtual system condition that one or more exit criteria identifiers of state table file item identify is checked 1212, and input 921 exit criterias determining whether to meet any mark 1214 according to current sequence controller, including any intervalometer being associated with current state。If be unsatisfactory for, then continue current state (being no 1214), and as it has been described above, program performs to return to 1206-1212。In this way, sequence controller 910 defines the state realizing given virtual sequential according to the state in respective table file item, until having met the one or more condition in the exit criteria specified。Once meet exit criteria (being yes 1214), 1216, processor 912 obtains next one controlled state list file item in proper order, the described list file item of the controlled state in proper order exit criteria identifier corresponding to meeting。It addition, perform instruction or routine 1216, they action identifier being arbitrarily designated corresponding to satisfying condition。Then, the execution process of control program 922 returns, in 1206 acquisition current system inputs 921 thus performing the output 923 corresponding with generation of the instructions of mark in new state table file item 1208 and 1210 respectively, and as it has been described above, to check new exit criteria 1212 and 1214。

It should be noted, with regard to selected state table file 924 interoperability for, sequence control program 922 is quite general, the hard coded instruction of its Program 922 and routine are suitable for being connected and controlling them with various system unit interfaces and be suitable for obtaining those instructions and the routine of input from them, and the concrete logic of given virtual sequential is provided by state table file item and key element thereof。In this way, the hard coded executable instruction that the virtual sequential logical AND in list file 924,926,928 controls program 922 is substantially separated mutually by embodiment with routine。It is therefore not necessary to recompilate and install software and firmware and without hardware modifications (such as, it is not necessary to amendment or recompility sequence control program 922), it is possible to complete reconfiguring of whole virtual system。On the contrary, it is possible to build state table file 924,926,928 and be simply stored in memorizer 920 (or being stored in the addressable data storage being arbitrarily suitable for of processing component 912), thus realizing new pseudo operation order。And, existing state table file 924,926,928 can serve as starting point or template, it is possible to revises from them, adds or remove state table file item to use controller 910 in proper order to realize new or amendment pseudo operation。Additionally, if sequencer state table file 924,926,928 creates outside memorizer 920, then this class file can be easily downloaded to the addressable data storage of processing component 912。In this regard, according to general inventive concept, virtual system operator or service personal can from remote location configuration sequence controllers 910 and therefore configure whole virtual system, wherein state table file 924,926,928 can be downloaded by network 930 and operability other networks connected, and described network includes LAN, WAN, the Internet connection etc.。Furthermore, it should be noted that, the key element of state table file item can be labelling, character string, pointer, address etc., which provides processor 912 intelligible instruction when execution sequence controls program 922, routine, numerical value, state or action。Therefore, the instrument 929 (Figure 10) that is arranged in order can be the hardware, software, firmware or their combination that are arbitrarily suitable for, its logic that can obtain key element and virtual sequential creation state list file 924,926,928 and item thereof, and then, these files and item may be used for performing pseudo operation。

Figure 13 is shown schematically in the exemplary embodiment of the virtual sequential including various welder (operator) and non-welder operation。In fig. 13, in operation 1310, virtual sequencer start operation and can the identification number of command operating person input operator, correct part mark number, assemble identification number etc.。Virtual welding equipment can also be arranged to use welding plan A (operation 1320) command operating person to perform welding #1, #2 and #3 virtually by virtual sequencer。Then, operator uses welding plan A to perform welding #1, #2 and #3 (operation 1322,1324 and 1326) virtually。Then, virtual welding equipment is arranged to use welding plan B (operation 1330) command operating person to perform welding #4 by virtual sequencer。Then, operator uses welding plan B (operation 1332) to perform welding #4。After welding plan B completes, virtual welding equipment is arranged to use welding plan C (operation 1350) command operating person perform welding #5 and #6 and check part with visual manner by virtual sequencer。Then, operator uses welding plan C to perform welding #5 and #6 (operation 1352 and 1354) the part checked or parts to confirm that it is correct (operation 1360)。This inspection can include size verification, dysopia confirms or is likely to the inspection of any other type of needs。Further, operation 1360 may include a requirement that, namely operator indicates this inspection to complete as passed through to press " OK " button being likely to advance to before next operates for certain。Finally, virtual sequencer indicates virtual welding operation terminate (operation 1370) and reset for next one operation。Data (include creation data) and can collect in all operations process。

Therefore, as noted above, sequencer completes or otherwise helps sequence and the plan of virtual welding operation, thus simulating reality world welding station。Automatically perform by virtual sequencer other operate can include such as changing fixture position, activate operation device, display vision helps, controls sound and visual detector, verifies some inspection etc.。Other guiding by the virtual sequencer of welder operator operate and can include such as retrieving exemplar, input exemplar ID, place exemplar in fixture, activate gripper jaws, perform test etc.。

Virtual sequencer can select based on various variablees and input and realize new function, as shown in fig. 13 that welding plan A, the selection of B and C and realization。Such as, virtual sequencer can simply choose new welding plan based on the time (moment after welding #3 in figure 13 above) in monitoring past since welding operation starts or since welding stops。Alternately, virtual sequencer can be monitored the weldment order of the action of operator, comparison and mark and properly select new welding plan。

Still it is possible to further realize various combination or any other effective method of these methods, as long as final effect is to simulate the environment in real world order and real world welding station。For example, and unrestrictedly, following real world function can be simulated in virtual welding station and include in void order。

Quality examination (QualityCheck) functional requirement performed the quality examination (in welding process or after welding completes) of welding before allowing the sequence of operation to proceed。Quality examination can be monitored various virtual welding parameter and can stop welding operation, and if be detected that extremely just warns operator。Can be arc data by the example of the welding parameter of this functional measurement。

Another exemplary functions is to repeat (Repeat) function。This function command operator repeats concrete virtual welding or welding sequence。The example using this function includes when the display of quality examination (QualityCheck) function is abnormal maybe when needing multiple example of same weld。

Another exemplary functions is to notify welder (NotifyWelder) function, and described function passes information to welder。This function by display information, provide acoustical signal or communicated with welder by certain other devices。The example using this function includes instruction operator, and he freely starts virtual welding, or instruction operator should with quality be objective check certain part of soldering part。

Another exemplary functions is input job information (EnterJobInformation) function。This functional requirement welder can proceed previously entered information at virtual sequencer, such as exemplar serial number, individual No. ID or other specific conditions。This information can also be passed through RFID, bar code scanning etc. and read from exemplar or inventory tag itself。Then, virtual sequencer can utilize the information of input to carry out virtual welding operation。The example using this function is to predict whole virtual welding operation, thus should select which plan and/or order to the instruction of virtual sequencer。

Another exemplary functions is workpaper (JobReport) function。This function can create the report about virtual weld job, and described report can include information, as: the timing of the number of times of the virtual welding of execution, total and independent electric arc, order interruption, error, fault, welding wire use, arc data etc.。Using the example of this function is the efficiency with regard to virtual process and quality aspect to workmanship Section report。

Another exemplary functions is systems inspection (SystemCheck) function。This function will establish whether virtual weld job can continue, and can detect following parameter: welding wire supply, gas supply, (compared with terminating this operation required time) remaining time etc. in shifts。Then this function may determine that whether these parameters have indicated time enough and/or material to proceed for virtual weld job。This functional simulation prevents the effort stopped work due to emptied of material, and the assembling that works in preventing from processing is delayed by, and this delay can cause quality problems due to heat and Plan Problem。

Further, as it has been described above, based on various variablees and input, virtual sequencer can select and realize new function。These variablees and input are not particularly limited and can even is that another kind of function。Such as, another exemplary functions compatible with virtual sequencer is carried out welding operation (PerformWeldingOperation) function。This function is designed to the virtual welding of detection operator's execution and reports that welds, and so makes virtual sequencer may determine whether further to operate。Such as, this function can operate in the following manner: when operator's tractive trigger is to initiate virtual welding behaviour, and after virtual welding completes or scheduled time slot pass by after operator terminate when discharging trigger。This function can terminate when trigger is released, or its may be configured to over time, the energy of some number of welding wire or certain amount is automatically switched off after being delivered。As discussed above, this function can be used to determine when to select new function, e.g., and new welding plan。

Still further, various semi-automatic and/or robot working unit can combine in single network, and the sequence in the virtual welding step of single working cell can be entirely integrated in the virtual complete production schedule, described plan itself can revise to follow the trail of the change of the virtual production schedule as required。Sequence and/or plan information can also be stored in data base, are archive information according to date storage, it is possible to be accessed to provide various virtual production to report。

Various training and operation optimization technology is can be used for above, including the course project based on following procedure with the example virtual welding station embodiment (including example virtual sequencer embodiment) being described in the drawings。Can collect in data base (coming self-virtualizing and real world operation) that is one or more shared or that separate, compare and manipulate production monitoring data。

Such as, Figure 14 is the flow chart illustrating exemplary training routine。Operator can perform the operation of virtual welding station before carrying out real world welding operation。

Figure 15 is the flow chart illustrating the exemplary training routine using virtual score。In this embodiment, before being operated in real world welding station, operator must reach certain mark。

Figure 16 is the flow chart illustrating the exemplary hiring process using virtual performance to measure。In this embodiment, applicant (operator) must use the virtual welding station that will employ to reach certain performance。

Figure 17 is the flow chart illustrating the exemplary optimized routine using virtual welding station。In this embodiment, virtual welding station is for certain aspect of the operation order of Optimizing Suggestions。Pseudo operation can be revised, until one or more aspects are acceptable (such as, exceed certain predetermined threshold value or meet one or more mass parameter)。Then, virtual sequential is used as real world order。

Figure 18 is the flow chart illustrating the exemplary training routine using virtual score and reality mark。In this embodiment, before being operated in real world welding station, operator must reach certain mark。Then, real world sequencer (such as, the welding sequencer of LincolnElectric company) is used in identical operation by same operator and uses, and determines real world mark。

Figure 19 is another flow chart illustrating the exemplary training routine using virtual score and real world mark。In this embodiment, before being operated in real world welding station, operator must reach certain mark。Then, it is determined that real world mark, and if real world mark drop below threshold value, operator can use virtual welding station to undergo training further。

Figure 20 is another flow chart, illustrates and uses virtual score and real world mark to determine the routine that how good phantom station prediction real world representation is。In this embodiment, relatively more virtual and real world representation mark is to determine how virtual analog predicts real world representation well。If dependency is not enough, it is possible to amendment virtual analog。

Visible, virtual welding station and virtual sequencer can be used for collecting and storing mass data, and these data can be used for calculating and finally improving productivity ratio。This data can be stored in data " cloud ", and is then accessed for analyzing and manipulation。Virtual sequencer can be monitored and instruction user prevents omitting solder joint, omit welding step, omit other operations, excessively uses welding consumptive material and other undesirable activities。Virtual sequencer can be also used at appropriate time training user to realize on concrete assembly or to complete various welding or non-solder step。Virtual sequencer also produces continuous print procedural order to manufacture special weldment assembly。Virtual sequencer also reduces training time and particle。It may also be determined that the number of times that each user must be undergone training on some assembly is to be the specifically used problematic part of person's labelling。All these make productivity ratio improve and less lose time and resource。

Although general inventive concept is illustrated already by the description of its different embodiments, although and described in detail these embodiments, but applicant is not intended to scope of the following claims constraint or is limited to this kind of details by any way。To those skilled in the art, attendant advantages and amendment will be apparent from。Therefore, shown in the present invention is not restricted in it is wider range of and described detail, typical equipments and method and illustrated examples。Therefore, when not necessarily departing from the spirit and scope of general inventive concept of applicant, it is possible to these details deviation to some extent。

Reference number

100 systems 182 assembling jig (AF)

110 subsystems (PPS) 184 exemplar (SP)

The 120 virtual sequencer of spatial pursuit devices (ST) 186 (VS)

121 magnetic source 188 sequencer display/user interface

122 sensors (SD/UI)

123 disk 189 screenshotss

124 power supplys 190 operate device

125 cable 514 tracks

126 tracing unit 516 tracks

130 welding user interface (WUI) 518 platforms

135 control station 520 surfaces

140 wear in display device (FMDD) 522 framework of face

150 observer's display device (ODD) 524 bands

160 simulation soldering appliance (MWT) 526 structures/supports

170 workbench/frame (T/S) 528 base

171 workbench 530 hinges

172 base 530c elements

173 arm 532c elements

174 column 530d elements

175 welding piece (WC) 532d element

180 welding piece (WC) 532 hinge

540 pivoting member

542 pivoting member 718 textures

550 component 719 functions

552 component 720 functions

554 pivoting member 721 functions

556 pivoting member 722 effects

560 component 723 models

562 element 902 systems

701 interface 910 controllers/sequencer

702 model 912 microprocessors

703 model 914 interfaces

704 function 916 interfaces

705 welding sound 918 interfaces

706 model 920 memorizeies

707 functions 921 control input

708 function 922 programs

709 models 923 control output

710 model 924 state table files

711 weld physics part 926 state table files

712 regulate device 928 state table file

713 function 930 networks

714 function 940 cables

715 function 941 cables

716 present device 942 cable

717 beads present 943 cables

944 cables 1174 check

945 cables 1202 check

946 cables 1204 check

947 cables 1206 check

950 parts 1208 check

951 power supplys 1210 check

952 wire feeders 1212 check

953 vehicle frames 1214 check

955 solenoid solenoids 1216 check

955 solenoid solenoids 1310 operate

956 extraction systems 1320 operate

957 programmable logic controller (PLC)s (PLC) 1322 operate

962 programs 1324 operate

1150 check 1326 operations

1152 check 1330 operations

1154 check 1332 operations

1156 check 1350 operations

1158 check 1352 operations

1160 check 1354 operations

1162 check 1360 operations

1164 check 1370 operations

1166 check AF assembling jig

1170 check that FMDD wears in the display device of face

1172 check that MWT simulates soldering appliance

ODD observer's display device ST spatial pursuit device

PLC programmable logic controller (PLC) T/S workbench/frame

PPS is based on the subsystem WC welding piece of programmable processor

SDUI sequencer display/user circle WUI welds face, user interface

The virtual sequencer SP exemplar of VS

Claims (16)

1. a virtual welding system (100), including:

The subsystem (110) of one logic-based processor, described subsystem can be used to the coded command performed for producing an interactive welding surroundings, the welding activity on a virtual plumb joint that described interactive welding surroundings simulation at least one in a welding piece (175,180) and an exemplar (184) limits；

One virtual sequential controller, described virtual sequential controller is operatively connectable to the subsystem (110) of described logic-based processor, is used for realizing a virtual sequential (186)；

Display device, described display device is operatively connectable to the subsystem (110) of described logic-based processor, for visually describing to include the described interactive welding surroundings of described virtual plumb joint；

One input equipment, it is shown that input equipment for carrying out virtual welding activity in real time on described virtual plumb joint；And

One spatial pursuit device (120), described spatial pursuit device includes one or more sensor (122), and the one or more sensor is adapted for the movement of input equipment described in real-time tracing the data relevant with the described movement of described input equipment to be transferred to the subsystem (110) of described logic-based processor。

2. virtual welding system (100) as claimed in claim 1, farther includes a user interface, provides input for a user to described virtual welding system (100)。

3. virtual welding system (100) as claimed in claim 1 or 2, wherein, the subsystem (110) of described logic-based processor is encapsulated in simulation welding control station (135), and size and the shape of described simulation welding control station are confirmed as an approximate source of welding current (124)。

4. virtual welding system as claimed any one in claims 1 to 3, wherein, described virtual sequential controller includes a microprocessor (512), a sequence control program and a memorizer (920), and

Wherein, described memorizer (920) stores one or more state table file。

5. the virtual welding system (100) as according to any one of Claims 1-4, wherein, described virtual sequential is defined by least one in described state table file, and/or

Wherein, a user is based on there being one of state table file described in a pending task choosing；And

Wherein, described task is to produce a complete virtual component。

6. the virtual welding system (100) as according to any one of claim 1 to 5, wherein, described virtual sequential (186) includes the multi-mode operation needing to be performed in order, and each operation aims at a particular state。

7. the virtual welding system (100) as according to any one of claim 1 to 6, wherein, at least one in described operation is that described user has a pending manual operation, and/or

Wherein, a manual operation is to provide user information, retrieval part, provides parts information, placement part, retaining element and provide the one in module information。

8. the virtual welding system (100) as according to any one of claim 1 to 7, farther includes a virtual sequential display device；

Wherein, described virtual sequential display device shows the information relevant with described manual operation。

9. the virtual welding system (100) as according to any one of claim 1 to 8, wherein, at least one in described operation is that described virtual welding system has the automatic operation of pending。

10. virtual welding system (100) as claimed in any one of claims 1-9 wherein, wherein, described automatic operation is appointment welding procedure, designated gas type, designated gas flow velocity, appointment welding rod type, appointment flux-cored wire type, appointment wire feed rate, specified voltage level, appointment amperage, appointment polarity and is the one in described interactive mode welding surroundings one background environment of appointment。

11. the virtual welding system (100) as according to any one of claim 1 to 10, wherein, each state is associated with a condition。

12. the virtual welding system (100) as according to any one of claim 1 to 11, wherein, if condition described in not met, described sequence controller performs an action。

13. the virtual welding system (100) as according to any one of claim 1 to 12, wherein, described display device is to wear in the display of face。

14. the virtual welding system (100) as according to any one of claim 1 to 13, farther include a supporting construction。

15. virtual welding system (100) as described in any of claims 14, wherein, described supporting construction is a frame, and described frame includes a base, a column, an adjustable bed and an adjustable arm, and/or

Wherein, described supporting construction is an assembling jig for holding described exemplar (184)。

16. the virtual welding system (100) as according to any one of claim 1 to 15, farther include to collect from described virtual sequential controller and store welding and the device of operation data, and/or

Farther include the device for distributing a mass fraction to described virtual welding activity。